Machine Protection is a main part of the PROGNOST®-SILver and also a part (module) of the PROGNOST®-NT. See the case studies which are telling you more about this topic.

Timely trip of a LDPE hyper compressor

2020-09-04T07:33:39+02:0031. May 2020|Customer Case Studies, Cases with PROGNOST®-NT, Featured, Hyper Compressor, News|

Monitored Machine The monitored machine is a secondary LDPE Hyper Compressor (high pressure compressor) in Ethylene service of LDPE production line. What happened? Sequence of events On March 29, the PROGNOST System tripped the Hyper compressor in consequence of high plunger vibration on cylinder 2AVertical position lead LDPE unit for total shut downThe Maintenance group of the customer, started the root cause analysis with assistance of the PROGNOST Systems Customer Support team, they analyzed the data and finally recommended to open the cylinder for inspection Trend over 60 minutes of plunger position Peak-to-Peak values Findings As a result of the cylinder opening the following findings where detected. In the plunger path way they found Chips of packing ring material.The packing [...]

Sensor locations on Reciprocating Compressors

2020-06-05T10:02:35+02:0018. February 2019|Intelligent Machine Monitoring, Multimedia library, News|

Best practices for sensor mounting to obtain perfect signals for Online Condition Monitoring and Machine Protection of Rotating Equipment. This includes acceleration sensors, velocity sensors for API compressors, displacement and pressure sensors.

Use of a Condition Monitoring System on a Hyper Compressor

2020-07-08T16:56:22+02:007. December 2018|Featured, Customer Case Studies, Hyper Compressor, Knowledge Hub, News, Online Condition Monitoring|

Mirko Graf (Innospec Leuna GmbH) showed this presentation during the 13th LDPE Plant Improvement Conference. He explained all the details about sensor positions and use. Also the first results of the 24 hour 365 days monitoring are shown and explained in the presentation. Some Processed topics which where explained About InnospecHyper CompressorCondition Monitoring SystemResistance Strain GaugesRod Position Sensors Standard Sensor Arrangements on Hypers Customised Sensor Arrangements on hydraulically-driven Hypers Download PDF: Implementation of CMS on a Hyper Compressor

Detection of a damaged crankshaft bearing

2020-06-05T09:47:36+02:0031. August 2018|Customer Case Studies, Cases with PROGNOST®-NT, Hyper Compressor, News, Online Condition Monitoring|

Information about monitored Machine Hitachi-Buckhardt Hyper Compressor F10 10 cylinders, 2 stages, in Ethylene service for LDPE production Speed: 189 rpm Power: 11 186 kW (15000 hp) Inlet pressure: 250 bar (3,626 psi) / Outlet pressure: 3.165 bar (45,904 psi) Hitachi-Buckhardt Hyper Compressor F10 Used Monitoring equipment and sensor positions Monitoring sensor positions What happened (Sequence of events)? Development of vibration increases over a time of 6 months. Long term trend over 6 months of the crosshead slide vibration of cylinder B1 in 3D plot Since May 30, for segments 31 and 32, vibration values increase from 2,5 m/s² (0.25 g) to over 10 m/s² (1 g) Segmented vibration plot Shutdown of [...]

Lube oil in compression chamber

2020-06-05T09:52:26+02:0031. August 2018|Customer Case Studies, Cases with PROGNOST®-NT, News, Reciprocating Machinery, Vibration Monitoring|

Machine data NEA (Neumann Esser) horizontal reciprocating compressor with 4 throws. 1 stage in Natural gas service. The Pressure for Inlet is 33 bar (479 psi) for Outlet 75 bar (1088 psi). NEA horizontal reciprocating compressor Used Monitoring Software Modules of PROGNOST®-NT Machine Protection Early Failure Detection Wear Monitoring Performance Optimization Process Data Integration Sequence of events PROGNOST Systems received a call from the customer. The compressor was shut down by the PROGNOST system shortly after start up. This was a result of protection limit violations on two measuring points. In detail the shutdown was triggered by increased vibrations at the crosshead guides 3 and 4, this affected segment 20 of crosshead slide (CHS) 3 and segment 19 [...]

Babbitt metal wear on crosshead

2020-06-05T09:44:14+02:0027. March 2018|Customer Case Studies, Cases with PROGNOST®-NT, Cases with PROGNOST®-SILver|

Machine data Manufacturer: ArielDrive power: 6150 kW (8636 hp)Speed: 700 rpm6 cylinderDouble acting, 2 stagesSuction pressure: 40 barDischarge pressure 240 bar Sequence of events: 3:45 AMPROGNOST®-SILver Protection hardware shut down the monitored compressor. Initiated because of piston rod position of cylinder 1. 5:02 AMPROGNOST®-SILver tripped the compressor again during start-up. Again due to rod position cylinder 1. 9:45 AMPROGNOST Customer Support recommends to make no restart, cause of high piston rod movement Screenshots from Online Condition Monitoring system PROGNOST®-NT 2 months 3D-trend of rod position 2 months 3D-trend of crosshead slide vibration Evaluation No long term indications on crosshead slide (CHS) and rod position (RP)No changing pressure gradientHigher dynamic in RP signalCHS peak nearly 2nd rod load reversal point decreasesCHS [...]

Early detection of rider band and piston ring failure

2020-06-05T09:48:58+02:0027. March 2018|Customer Case Studies, Cases with PROGNOST®-NT, Online Condition Monitoring|

Shutdown due to high values of Peak-To-Peak and Piston rod position of the Booster cylinder. Monitored compressor Booster Primary, Burckhardt Compression B5C 1.654 cylinders, 5 stagesSuction pressure (0,6 bar)Discharge pressure (245 bar) Trend November 2015 Rod position values October - November 2015 Meaningful analysis and display Segmented piston rod position in 3D trend view Root cause analysis Findings

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